Semi-product for lighting purposes, a method and an apparatus for the production of such product

ABSTRACT

This invention pertains to a method for producing a semi-product for lighting purposes. The semi-product is produced by forming fields or stripes on a substrate, and then shaping the substrate into a configuration. The fields or stripes exhibit different lighting and/or aesthetic properties.

[0001] This application is a divisional of U.S. application Ser. No. 09/446,723, filed Dec. 23, 1999.

BACKGROUND OF THE INVENTION

[0002] The present invention concerns a procedure for producing an intermediate product for lighting purposes, a semi-product for lighting purposes and equipment for producing the semi product for lighting purposes.

[0003] A semi-product for lighting purposes may comprise reflecting elements and possibly exterior elements such as housings, lids, etc. These semi-products comprise sub-components which, together with electrical equipment, may be assembled to form a complete fixture or lamp.

[0004] In connection with the manufacture of lamps or fixtures, it is known to produce a housing and a reflector separately and then to assemble these parts. Such products may be fashioned by a panel-shaped material being surface-treated followed by processing and forming to obtain the desired geometry or vice versa. For such products, lustering and anodizing are the most common surface treatments for the reflector part while lacquering is the most common surface treatment for the exterior part.

[0005] If a fixture is to have a varied or complex surface finish, this may be fashioned, according to the prior art, by using various components which produce the desired lighting and/or aesthetic effects.

[0006] The above methods are, however, labor-intensive and cost-intensive and will also result in the finished product having a high price.

SUMMARY OF THE INVENTION

[0007] With the present invention, the above disadvantages can be avoided. Furthermore, semi-products with complex surface finishes may be fashioned without the need to use several components. In accordance with the present invention, it is possible to produce the reflector and the exterior from one component, which results in reduced production costs. Moreover, it is possible to produce reflector elements with a complex surface finish and with completely new lighting properties. Reflectors fashioned in accordance with the present invention will find it easier to meet international requirements and wishes for energy economy.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will be described below by way of examples and figures where:

[0009]FIG. 1 shows an example of a coated substrate before forming,

[0010]FIGS. 2a-2 b show examples of reflector elements which may form part of a fixture,

[0011]FIGS. 3a-3 d show an example of forming a reflector and fixture housing in one piece.

[0012]FIG. 1 shows a substrate 10 of metal, preferably aluminum or an aluminum alloy, which is treated or coated in fields or stripes with a coating of the desired lighting character. In this example, the substrate's stripes are distributed symmetrically around the center. Thus the outer stripes 1 may be fashioned from a lacquer which produces the desired aesthetic surface finish. This may, for example, comprise a lacquer containing color pigments. When subsequently formed, these parts will form the exterior sides of the housing or fixture. It should be noted here that the substrate may also comprise other expedient materials, for example steel or plastic materials.

[0013] Between the outer stripes it is possible to apply one or more types of stripes or fields 2 which have different light-distributing or aesthetic properties. Such fields may comprise a coating which may include lacquers with added particles which change the distribution of light. Alternatively, transparent lacquers with different degrees of luster from high luster to half luster may be used or the surface may be metalized. Moreover, it should be mentioned that the fields may be fashioned in different ways, for example stripe lacquering, possibly followed by metalization or anodization followed by stripe lacquering, stripe stamping, stripe printing or stripe lamination.

[0014] Another method for producing the light-distributing fields 2 may be to use stripe stamping or embossing (not shown). This method changes the surface topography and thus the lighting and aesthetic properties of the material.

[0015] One or more stripes 2, 3 between the fields which make up the exterior part may constitute the reflector and will thus be fields with the desired lighting properties. Field 3 may comprise an area with high luster, where, for example, the substrate material is fashioned by chemical or electrochemical brightening followed by lacquering or anodizing. The anodizing may be performed with a well-defined oxide layer thickness, which results in a better reflectiveness than with standard anodizing or lacquering.

[0016] The present invention is not limited to a symmetrical distribution of the stripes on the substrate or a fixed number of different stripes. It is also possible to fashion semi-products which comprise solutions in which the fields with lighting properties can be positioned in another way; this may depend, among other things, on the design of the lighting arrangement.

[0017] Preferably, a strip substrate which is wound or on a coil (not shown) is used. The advantage of this is that the process can be continuous and the strip substrate can be lengthened without stopping the process. At the same time, it should be noted that sheets may also be used as the substrate.

[0018] The various coatings can be fashioned and the various treatments may be applied expediently using known techniques. Alternatively, the substrate may be subjected to treatment/coating across its entire width before the stripes are fashioned. Thus the substrate may be lacquered or anodized before the stripe lacquering. The stripes may be fashioned in different operations. The special aspect of the coating in accordance with the present invention is that fields of the desired width may be fashioned with different lighting and/or aesthetic properties.

[0019] The equipment for coating the semi-product for lighting purposes may expediently comprise a strip lacquering machine with a coating/treatment station 20 with a pick-up roller 21 which collects the lacquer from a reservoir 22 or has lacquer applied to its top and one or more rollers 23 which apply lacquer to the substrate 10 and possibly one or more transfer rollers (not shown) which are mounted between the stated rollers; the application roller(s) 23 have a width which is less than the width of the substrate. The equipment may also comprise an adjustment roller 27. Moreover, the application roller may have milled grooves 25 so that lacquer is only applied to the substrate in the areas of the roller which do not have grooves. Alternatively, several application rollers mounted on a joint shaft 26 can be used, with the application rollers being at equal distances from each other in the transverse direction. Moreover, the rollers may comprise means which allow them to be controlled individually with regard to direction of rotation and speed of rotation (not shown).

[0020] It may be mentioned that the substrate may be treated/coated on both sides. A strip substrate on a coil may, in connection with the fashioning of the lighting/aesthetic properties, pass through the treatment line and be wound before being turned and passed through a new treatment. Alternatively, the substrate may be coated on both sides in one pass through the treatment line. The strip may first be treated/coated on its top in a first stage and be treated on its bottom in a second stage or vice versa. In connection with treatment/coating of the top and bottom of the substrate, the fields with different lighting/aesthetic properties must be placed on the substrate in such a way that they are in the desired location when the substrate is subsequently formed to create the intermediate product. Thus, for example, one side of the substrate may constitute the exterior of the intermediate product and be coated with a lacquer with color pigments. The other side of the substrate may be treated/coated so that fields with light-distributing and reflecting properties are fashioned in the semi-product.

[0021]FIG. 2a shows a semi-product 14 which, in this case, has two fields 2, 3 with different light-distributing properties. The semi-product shown may, for example, be mounted beside a long light source such as a fluorescent tube in a housing (dotted). FIG. 2b shows an equivalent semi-product 15 for use as a cross mirror or lamella. In this way, the semi-product comprising two or more lighting/aesthetic properties may be used as a reflector in a lighting product.

[0022]FIGS. 3a-3 d show an example of forming a substrate into a semi-product which comprises both a reflector and a fixture housing. It has been shown that it is possible using the above treatment/coating techniques, to fashion a substrate treated/coated with stripes/fields which can be exposed to fairly large stresses/deformations without the coatings cracking or the treated areas deteriorating. This produces major advantages during manufacture as the substrate can first be coated/treated and then processed/formed to the desired form at a processing station. The figures illustrate, via a cross-section through the substrate, the forming of a plane substrate to create a semi-product 12 by using three forming stages, b, c and d. More than three forming stages may, naturally, be used if this is favorable.

[0023] The forming is performed preferably by a treated/coated substrate on a coil being fed into a roll-forming unit either directly from the surface treatment unit or after first having been wound on a coil. The roll-forming unit may consist of one or more forming stages. It is expedient to use several stages which produce a gradual deformation of the substrate until the final form has been obtained. In this way, it will be possible to make semi-products from substrates which undergo major deformations in connection with the forming without the surface treatment/coating being weakened or deteriorating.

[0024] If the width of the substrate so allows, it is possible to fashion several sets of stripes/fields in the width of the substrate. In this case, the substrate will be split before passing into one or more roll-forming units or is possibly wound.

[0025] It can be mentioned that another method of forming the substrate is to cut the substrate into the desired lengths and form it to the desired geometry in one or more stages by using known forming methods such as buckling, bending, roll-forming and deep drawing.

[0026] Alternatively, the surface treatment may be transverse to the substrate. In this case, the substrate is cut transversely between each section of stripes/fields. Piece-by-piece forming of these panels can then take place as stated above. The application equipment may comprise rollers with grooves which run transversely to the substrate/band. It is then expedient for the stripes/fields to be fashioned by printing.

[0027] It should be understood that application equipment other than rollers may also be used within the framework of the attached claims. For example, the fields may be fashioned by using spray equipment which sprays coatings onto the substrate (not shown).

[0028] After the forming operation, the mounting of the semi-product may be completed by fitting it with electrical equipment and possibly prefabricated gables. The gables may be treated externally in accordance with the outer coating of the housing (for example, lacquer with pigments) and possibly internally with a light-distributing or reflecting coating. The means of fastening for assembling the intermediate product and the gables and electrical equipment may expediently comprise glue, nails, screws, snap fasteners, etc. 

1. A method for producing a semi-product for lighting purposes, comprising: forming fields or stripes on a substrate, wherein said fields or stripes exhibit different lighting and/or aesthetic properties; and then shaping said substrate into a configuration.
 2. The method according to claim 1, wherein forming fields or stripes on a substrate comprises forming fields or stripes on a planar substrate.
 3. The method according to claim 2, wherein forming fields or stripes on a planar substrate comprises forming fields or stripes on a strip which is coiled prior to forming the fields or stripes thereon.
 4. The method according to claim 3, wherein forming fields or stripes on a strip which is coiled prior to forming the fields or stripes thereon comprises forming fields or stripes on an aluminum or aluminum alloy strip.
 5. The method according to claim 4, wherein forming fields or stripes on an aluminum or aluminum alloy strip comprises forming fields or stripes on opposite surfaces of said aluminum or aluminum alloy strip.
 6. The method according to claim 5, wherein forming fields or stripes on opposite surfaces of said aluminum or aluminum alloy strip comprises forming fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip in a longitudinal direction of said aluminum or aluminum alloy strip.
 7. The method according to claim 6, further comprising slitting said aluminum or aluminum alloy strip along said longitudinal direction prior to shaping said substrate into said configuration.
 8. The method according to claim 7, further comprising cutting said substrate to a desired length after shaping said substrate into said configuration.
 9. The method according to claim 8, wherein shaping said substrate into said configuration comprises continuously roll forming said substrate into said configuration.
 10. The method according to claim 9, wherein forming fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip in a longitudinal direction of said aluminum or aluminum alloy strip comprises coating fields or stripes on said opposites surfaces of said aluminum or aluminum alloy strip.
 11. The method according to claim 10, wherein coating fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip comprises rolling fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip.
 12. The method according to claim 5, further comprising slitting said aluminum or aluminum alloy strip along a longitudinal direction of said aluminum or aluminum alloy strip prior to shaping said substrate into said configuration.
 13. The method according to claim 12, further comprising cutting said substrate to a desired length prior to shaping said substrate into said configuration.
 14. The method according to claim 13, wherein forming fields or stripes on opposite surfaces of said aluminum or aluminum alloy strip comprises coating fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip.
 15. The method according to claim 14, wherein coating fields or stripes on said opposite surfaces of said aluminum alloy strip comprises rolling fields or stripes on said opposite surfaces of said aluminum or aluminum alloy strip.
 16. The method according to claim 4, wherein forming fields or stripes on opposite surfaces of an aluminum or aluminum alloy strip comprises forming fields or stripes on said aluminum or aluminum alloy strip in a longitudinal direction of said aluminum or aluminum alloy strip.
 17. The method according to claim 16, further comprising slitting said aluminum or aluminum alloy strip along said longitudinal direction prior to shaping said substrate into said configuration.
 18. The method according to claim 17, further comprising cutting said substrate to a desired length after shaping said substrate into said configuration.
 19. The method according to claim 18, wherein shaping said substrate into said configuration comprises continuously roll forming said substrate into said configuration.
 20. The method according to claim 4, further comprising slitting said aluminum or aluminum alloy strip along a longitudinal direction of said aluminum or aluminum alloy strip prior to shaping said substrate into said configuration.
 21. The method according to claim 20, further comprising cutting said substrate to a desired length prior to shaping said substrate into said configuration.
 22. The method according to claim 1, wherein forming fields or stripes on a substrate comprises coating fields or stripes on said substrate.
 23. The method according to claim 22 wherein coating fields or stripes on said substrate comprises rolling fields or stripes on said substrate. 